Vehicle panel

ABSTRACT

A vehicle panel with a folded-over or wrapped edge is disclosed. The vehicle panel comprises a main body portion. The main body portion includes a first layer and a second layer. The first layer is formed of a substantially rigid material and has a first surface, a second surface and an edge. The second layer is coupled to the second surface of the first layer and formed of a substantially flexible material. The vehicle panel also comprises a flap integrally formed with the main body portion at the edge and comprises at least the second layer. The vehicle panel further comprises a hinge separating the flap from the main body portion, the hinge is defined by at least a portion of the first layer having a reduced thickness. The flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims the benefit under 35 U.S.C. §119(e) of U.S.Provisional Application No. 60/935,413, having a filing date of Aug. 10,2007, titled “Vehicle Headliner,” the complete disclosure of which ishereby incorporated by reference.

BACKGROUND

The present disclosure relates generally to a panel for a vehicle. Morespecifically, the present disclosure relates to a panel, such as aheadliner, having a wrapped or folded-over edge and a method ofmanufacturing a panel with a wrapped or folded-over edge.

Headliners are vehicle panels that are coupled to a support structure orroof of a vehicle. Headliners may include one or more peripheral edgesthat are visible to an occupant within the vehicle. Headliners may alsoinclude one or more edges that define an opening in the headliner, suchas an opening for a sunroof. In certain applications it may be desirableto provide one or more of these edges with a finished appearance so asto improve the aesthetics within the vehicle for the vehicle occupant.It may also be desirable to provide one or more of these edges with astructural or reinforcement member. For example, as sunroofs increase insize (e.g., panoramic sunroofs, etc.), there is less and less headlinermaterial surrounding them, which may lead to weaker headliners that havea tendency to fold or crack alongside the sunroof opening. Secondaryreinforcements may be added to the headliner to strengthen the headlineraround the sunroof opening. Such reinforcements are generallymanufactured separately with an injection molding or vacuum-formingprocess and can be costly. There continues to be a need to improve theconfiguration of vehicle panels, including vehicle headliners,particularly the edges of vehicle panels.

SUMMARY

One embodiment relates to a vehicle panel. The vehicle panel comprises amain body portion. The main body portion includes a first layer and asecond layer. The first layer is formed of a substantially rigidmaterial and has a first surface, a second surface and an edge. Thesecond layer is coupled to the second surface of the first layer andformed of a substantially flexible material. The vehicle panel alsocomprises a flap integrally formed with the main body portion at theedge and comprises at least the second layer. The vehicle panel furthercomprises a hinge separating the flap from the main body portion, thehinge is defined by at least a portion of the first layer having areduced thickness. The flap is folded back about the hinge towards thefirst surface of the first layer to substantially conceal the edge.

Another embodiment relates to a method of manufacturing a vehicle panel.The method comprises forming a main body portion having a substantiallyrigid substrate and a substantially flexible cover material coupled tothe substrate. The substrate has an edge. The method also comprisesproviding an area of reduced thickness in the substrate. The area ofreduced thickness defines a living hinge. The method further comprisesintegrally forming a flap with the main body portion. The flap isprovided on a side of the living hinge opposite the main body portionand comprises at least the cover material. The method further comprisesfolding the flap about the living hinge towards the substrate of themain body portion to substantially conceal the edge.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a vehicle according to an exemplaryembodiment.

FIG. 2 is an isometric view of the interior of the vehicle of FIG. 1showing a headliner according to an exemplary embodiment.

FIG. 3 is a bottom plan view of a headliner according to an exemplaryembodiment and including an opening for a sunroof.

FIG. 4 is a partial bottom plan view of the headliner of FIG. 3 showingan edge of the headliner around the opening before it has been finished.

FIGS. 5A and 5B are cross-sections of a portion of a headliner showing aflap according to an exemplary embodiment being folded back onto theheadliner.

FIGS. 6A and 6B are cross-sections of a portion of a headliner showing aflap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 7A and 7B are cross-sections of a portion of a headliner showing aflap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 8A and 8B are cross-sections of a portion of a headliner showing aflap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 9A and 9B are cross-sections of a portion of a headliner showing aflap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 10A and 10B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 11A and 11B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 12A and 12B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 13A and 13B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 14A and 14B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 15A and 15B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 16A and 16B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

FIGS. 17A and 17B are cross-sections of a portion of a headliner showinga flap according to another exemplary embodiment being folded back ontothe headliner.

DETAILED DESCRIPTION

Referring generally to FIGURES, exemplary embodiments of a panel for usein a vehicle (e.g., automobiles such as cars, trucks, sport utilityvehicles, minivans, buses, and the like; airplanes, boats, etc.) areshown. The vehicle panel includes one or more edges (e.g., peripheraledges, internal edges, etc.) that include a folded-over or wrapped edge.The folded-over or wrapped edges may be provided for aesthetic purposesand/or functional purposes. For example, the folded-over or wrappededges may function as a reinforcement member that improves the strengthand/or rigidity of the vehicle panel. The folded-over or wrapped edgemay also prevent creases from propagating from the edge and further helpto reduce the chance of fabric fraying along an edge. Such vehiclepanels may be installed at any suitable location within a vehicle (e.g.,side walls, floors, headliners, etc.) and integrated with any othervehicle component. The vehicle panels may be provided in a wide varietyof sizes, shapes, and configurations, and made from a wide variety ofmaterials and manufacturing processes according to various exemplaryembodiments. All such variations are intended to be within the scope ofthe inventions.

Referring to FIGS. 1 and 2, the vehicle panel is shown according to anexemplary embodiment as a headliner 100 that is configured to besupported at or coupled to the roof of a vehicle 10. According to theembodiment illustrated, the headliner 100 includes an opening 102 for asunroof (e.g., a panoramic sunroof, vista roof, etc.). The portions ofthe headliner 100 surrounding the opening 102 may be relatively narrowand/or may have a tendency to crack or bend, especially if the opening102 is for a larger sunroof (e.g., a panoramic sunroof). According tothe various alternative embodiments, the headliner 100 may includeadditional openings (e.g., for a second sunroof, for an attachmentopening, etc.) or may be a substantially continuous panel without anyopenings.

FIG. 3 shows a plan view of the headliner 100 according to an exemplaryembodiment. The headliner 100 includes one or more edges that define theperiphery of the headliner 100. For example, the headliner 100 is shownas including a first or front peripheral edge 114, a second or rearperipheral edge 116, a third or driver-side peripheral edge 118 and afourth or passenger-side peripheral edge 120. The opening 102 for thesunroof is defined by a first boundary, shown as a front edge 104, asecond boundary, shown as a rear edge 106, a third boundary, shown as adriver-side edge 108, and a fourth boundary, shown as a passenger-sideedge 110. The front edge 104, the rear edge 106, the driver-side edge108 and the passenger-side edge 110 cooperate to define a substantiallyrectangular opening for the sunroof. The headliner 100 is also shown asincluding an number of additional openings for receiving variouscomponents (e.g., fasteners, grab handles, pillars, overhead consoles,etc.) upon installation of the headliner 100. For example, the headliner100 includes an opening 112 configured to receive a support member for avisor assembly.

Referring to FIG. 4, the opening 102 for the sunroof may be formedduring a molding process or may be formed in a secondary operation byremoving a portion of the headliner material (e.g., scrap, offal, etc.).If the opening 102 is formed by removing a portion of the headlinermaterial, the material removed may be used elsewhere in the vehicle. Forexample, the headliner material may be used to construct seat backs,side panels for a floor console, or door panel speaker enclosures.Further, a substrate of the headliner material (i.e.,fiberglass-reinforced polypropylene, etc.) may make scrap materialuseful for other purposes such as forming totes, outdoor storagecabinets, drink trays, sleds, whiteboards or office panels. For suchuses, the substrate may be wrapped with other materials (e.g., vinyl,fabric, etc.) or may not be wrapped with any covering. Such reuse of thescrap from the headliner may help to reduce the amount of material thatis discarded.

According to an exemplary embodiment, one or more flaps (e.g.,extensions, strips, etc.), shown as a front flap 122, a passenger sideflap 124 and a corner flap 126, are provided after the opening 102 hasbeen formed. The flaps are coupled to the main body of the headlineralong the edges of the opening 102 and may be folded back onto theheadliner 100 to provide a folded-over or wrapped edge for aestheticpurposes and/or to form a reinforcement member or an integratedstiffener. According to an exemplary embodiment, the flaps areintegrally formed with a main body 128 of the headliner 100 and formedof substantially the same material(s) as the main body 128. According tothe various alternative embodiments, the flaps may be separate membersthat get attached to the main body 128. For example, the flaps may betrimmed from the main body 128 or any other panel and attached to themain body 128 near an edge with a suitable process (e.g., reheating thematerial, adhesives, sewing, ultra-sonic welding, etc.).

In addition to providing reinforcement for the headliner 100, the flapsmay provide further functional benefits. For example, the flaps may beconfigured to provide a head impact counter measure, an attachment areafor other body panels, an attachment area for coupling the panel to thevehicle framework or structure, or an attachment area for variousvehicle components (e.g., overhead system components, etc.).

According to an exemplary embodiment, the flaps are provided on eachside of the headliner 100 that defines the opening 102 (e.g., around theentire periphery of the opening 102, etc.). According to the embodimentillustrated, the flaps provided along the lengths of the opening 102(i.e., the front flap 122 and the passenger side flap 124, etc.) aregenerally rectangular in shape and have a depth sufficient tosubstantially wrap or conceal the adjacent edge. For example, the flaps122, 124 may have a depth between approximately 15 and approximately 20millimeters wide after being trimmed, but according to the variousalternative embodiments, may be any suitable size depending on theparticular application. The corner flap 126 is shown as including aplurality of sections or darts which will allow the combination of flapsto provide the appearance of a substantially continuous edge when foldedback onto the headliner 100 and secured thereto.

Configuring the flaps 122, 124 and/or 126, referred to hereunder as justthe flap 122 for simplicity, as a reinforcement member may minimize oreliminate cracking of the headliner 100 between the sides of the opening102 and the peripheral edges of the headliner 100. Configuring the flap122 for aesthetic purposes may provide the appearance of a substantiallycontinuous and cleanly wrapped (e.g., fabric wrapped, etc.) or finishededge. According to various alternative embodiments, the flap may not beconfigured to extend continuously around the opening 102. For example,the flap may only be provide on one or more side or lateral edges of theopening 102 (e.g., a driver-side flap and a passenger side flap, etc.).

The flap 122 may be provided in other locations besides around theopening 102 for the sunroof. For example, the headliner 100 may includethe flap 122 on any exposed edges such as the front peripheral edge 114,the rear peripheral edge 116, the driver-side peripheral edge 118, thepassenger-side peripheral edge 120, and/or around pillar trim areas.According to such embodiments, the flap 122 may be folded back upon theheadliner 100 and secured thereto to form fabric-wrapped edges at thefront peripheral edge 114, the rear peripheral edge 116, the driver-sideperipheral edge 118, the passenger-side peripheral edge 120, and/oraround pillar trim areas. A similar folded-edge may be used along theperiphery and/or internally with other vehicle components or panels(e.g., trim panels, such as those for a pillar or a door panel, etc.).

To achieve the folded-over or wrapped edge, the headliner 100 may beformed using a variety of processes including, but not limited to, athermofold process, an action in the molding tool to complete thefolding, scoring or machining the headliner 100, overcompressing eitherface surface of the headliner 100, using a heated tool, using a heatedrollform tool, die trimming the headliner 100, or shaping the flap tomatch the contours of the back surface of the headliner 100 and foldingthe flap over onto the back of the headliner 100.

Referring to FIGS. 5A and 5B, an exemplary embodiment of a cross-sectionof a portion of the headliner 102 is shown before and after the flap 122has been folded against a main body 128 of the headliner 100,respectively. As shown in FIG. 5A, the flap 122 may include a contourthat forms a structural shape that may be more effective in reinforcingthe headliner 100. According to the embodiment illustrated, when theflap 122 is folded back onto the main body 128, a space or channel 130is provided between the flap 122 and the main body 128 of the headliner100. For example, the channel 130 is shown as a generally C-shapedchannel. The channel 130 may also provide a conduit for one or morevehicle systems or components (e.g., wiring harnesses, HVAC systems,etc.). It should be noted that while the flap 122 is shown as providinga reinforcement member for the headliner 100 to which the flap 122 isintegrally formed therewith, according to other exemplary embodiments,the flap 122 may be removed and used as a reinforcing member for anotherheadliner.

Referring to FIGS. 6A through 17B, further exemplary embodiments ofcross-sections of a portion of the headliner 102 are shown before andafter the flap 122 has been folded against the main body 128 of theheadliner 100, respectively. According to the embodiments illustrated,the headliner 100 is generally formed of a first layer or portion, shownas a substrate 132, and a second layer or portion, shown as a covermaterial 134 (e.g., coverstock, etc.). According to an exemplaryembodiment, the substrate 132 is formed of a substantially rigidmaterial that provides at least some structural support for theheadliner 100. For example, the substrate 132 may be formed of a polymer(e.g., polyurethane, polypropylene, etc), a composite such as afiberglass-reinforced polymer, or any other material known in the art.According to an exemplary embodiment, the cover material 134 is formedof a substantially flexible material (e.g., a fabric material, etc.)that may be selected for its aesthetics.

The substrate 132 includes a first surface 136 and an opposite secondsurface 138. The first surface 136 is configured to face and/or becoupled to the vehicle structure, while the second surface is configuredto face the occupant compartment of the vehicle. The cover material 134is configured to be supported at the second surface 138 of the substrate132. According to an exemplary embodiment, the cover material 134 isadhered to the substrate 132, but alternatively, may be coupled tosubstrate 132 using any other suitable technique.

According to an exemplary embodiment, the headliner 100 includes one ormore features that allow the flap 122 to be folded back onto the mainbody 128 of the headliner 100 with a single step after formation (e.g.,molding, etc.) of the headliner 100. According to the embodimentsillustrated, such a feature is an area of reduced thickness in thesubstrate 132, shown as a recess 140. According to an exemplaryembodiment, the recess 140 functions as a hinge (e.g., a living hinge,etc.) that facilitates of the movement of the flap 122. According to thevarious alternative embodiments, the recess 140 may also be provided forornamental applications. For example, the recess 140 may allow theheadliner 100 to include fabric-wrapped ornamental features such asstyling lines, logos or other designs. The recess 140 may also be usedfor a functional application. For example, the recess 140 may be usedfor forming doors or panels that are configured to rupture to allow anairbag to inflate into the interior of the vehicle.

The recess 140 may be formed during a molding process of the substrate132 or as a secondary operation after the substrate 132 has been formed.For example, the recess 140 may be formed during a molding process ofthe headliner 100 by providing a projection with a small radius or someother shape in a surface of the form tool. Forming the recess 140 as asecondary operation may be achieved by milling a portion of thesubstrate 132. For example, a portion of the substrate 132 could beremoved using a waterjet or some other machining device. Anothersecondary operation technique that could be used to form the recess 140is overcompressing the substrate 132 in such an area. According to anexemplary embodiment, the substrate 132 is thinned between approximately20 percent to approximately 30 percent relative to the thickness of thesubstrate 132 to form to form the hinge.

Referring to FIGS. 6A and 6B in particular, the recess 140 is in theform of a double hinge. According to an exemplary embodiment, the recess140 is formed during the molding process of the substrate 132 andincludes a stepped profile in the first surface 136 of the substrate132. Configuring the recess 140 as a double hinge may simplify foldingover the flap 122 and/or reduce the likelihood of unwanted creases,bulges, and/or other imperfections after the folding is complete.According to an exemplary embodiment, the headliner 100 is configured tobe trimmed or cut at a trim line 142 before the flap 122 is folded over.

Referring to FIGS. 7A and 7B, the trim line 142 is within the recess 140or at a boundary of the recess 140. In such an embodiment, when the flap122 is folded back towards the substrate 132, the folded-over or wrapedge includes a portion of the substrate 132 (i.e., the portionassociated with the flap 122, etc.) that functions as a reinforcementmember for the headliner 100. The reinforcement member has a thicknessthat is less than the thickness of the substrate 132 of the main body128.

Referring to FIGS. 8A and 8B, the recess 140 is formed by substantiallyremoving all of the substrate 132 (e.g., via a secondary operation,etc.) and, similar to the embodiment illustrated in FIGS. 7A and 7B, thetrim line 142 is within the recess 140 or at a boundary of the recess140. Such an embodiment, results in a folded-over or wrapped edge thatdoes not include a portion of the substrate 132 acting a reinforcementmember. It should be noted that even without a portion of substrate 132provided on the flap 122, the flap 122 may still provide reinforcementfor the headliner 100 with just the cover material 134. For example, thecover material 134 alone may provide some reinforcement at the edge bybeing tensioned over the edge.

Referring to FIGS. 9A and 9B, the headliner 100 is similar to that shownin FIGS. 8A and 8B, except that the trim line 142 is located past therecess 140. In such an embodiment, when the flap 122 is folded backtowards the substrate 132, the folded-over or wrap edge includes aportion of the substrate 132 (i.e., the portion associated with the flap122, etc.) that functions as a reinforcement member for the headliner100. The reinforcement member has a thickness that is substantially thesame as the thickness of the substrate 132 of the main body 128.

Referring to FIGS. 10A and 10B, the headliner 100 includes a structuralmember, shown as a trim ring 144, to assist in moving the flap 122 tothe folded-over or wrapped position. According to an exemplaryembodiment, the trim ring 144 is added during a molding process (e.g.,insert molded, etc.) behind the first surface 136 of the substrate 132.A free end (e.g., an upper end, etc.) of the trim ring 144 defines thatarea about which the flap 122 is folded over.

Referring to FIGS. 11A and 11B, the recess 140 is formed byovercompressing the substrate 132. Overcompressing the substrate 132reduces the thickness of the substrate 132 thereby creating the recess140 and providing a hinge for folding over the flap 122. Theovercompressing process may be completed in a secondary operation usinga tool, shown as an indenter 146, that gets retracted after the processis complete.

Referring to FIGS. 12A and 12B, the recess 140 is formed in the secondsurface 138 of the substrate 132. According to an exemplary embodiment,the recess 140 is formed during a molding process. Similar to theembodiment shown in FIGS. 12A and 12B, the trim line 142 is located pastthe recess 140 to provide a reinforcement member for the headliner 100after the flap 122 is folded over.

Referring to FIGS. 13A and 13B, the flap 122 is shown as being foldedback using a roll form die tool 148. Referring to FIGS. 14A and 14B, therecess 140 is formed in a secondary operation using a waterjet 150 andthe flap 122 is folded back using a slide tool 152. Referring to FIGS.15A and 15B and FIGS. 16A and 16B, in addition to the trim line 142, asecond trim line 154 is provided. The second trim line 154 is a partialcut as it does not extend through the cover material 134. The secondtrim line 154 defines the point at which the flap 122 is configured tobe folded about. In FIGS. 16A and 16B, the substrate 132 on the flap 122is removed before the flap 122 is folded back towards the substrate 132of the main body 128. Referring to FIGS. 17A and 17B, the recess 140 isformed in the second surface 138 of the substrate 132 similar to theembodiment illustrated in FIGS. 12A and 12B. In such an embodiment, anadditional recess is also provided in the cover material 134 to furtherassist in folding the flap 122.

For purposes of this disclosure, the term “coupled” means the joining oftwo members directly or indirectly to one another. Such joining may bestationary in nature or moveable in nature and/or such joining may allowfor the flow of fluids, electricity, electrical signals, or other typesof signals or communication between the two members. Such joining may beachieved with the two members or the two members and any additionalintermediate members being integrally formed as a single unitary bodywith one another or with the two members or the two members and anyadditional intermediate members being attached to one another. Suchjoining may be permanent in nature or alternatively may be removable orreleasable in nature.

It is important to note that the construction and arrangement of the ofthe various embodiments of the vehicle panel and the methods ofmanufacturing the vehicle panel provided herein is illustrative only.Although only a few exemplary embodiments of the present inventions havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible in these embodiments (such as variations inshape and size of the panel, the flap(s), various locations for mountingwithin the vehicle, etc.) without materially departing from the novelteachings and advantages of the inventions. Further, elements shown asintegrally formed may be constructed of multiple parts or elements, theposition of elements may be reversed or otherwise varied, and the natureor number of discrete elements or positions may be altered or varied.Further, the vehicle panel and method of manufacturing the vehicle panelmay be used in any type of vehicle such as trucks, recreationalvehicles, minivans, sport utility vehicles, passenger automobiles, etc.and at any suitable location within the vehicle. Accordingly, all suchmodifications are intended to be within the scope of the invention asdefined in the appended claims.

The order or sequence of any process or method steps may be varied orre-sequenced according to alternative embodiments. In the claims, anymeans-plus-function clause is intended to cover the structures describedherein as performing the recited function and not only structuralequivalents but also equivalent structures. Other substitutions,modifications, changes and omissions may be made in the design,operating configuration and arrangement of the preferred and otherexemplary embodiments without departing from the spirit of theinventions as expressed in the appended claims.

What is claimed is:
 1. A vehicle panel comprising: a main body portionincluding a first layer and a second layer, the first layer being formedof a substantially rigid material and having a first surface, a secondsurface and an edge, the second layer being coupled to the secondsurface of the first layer and formed of a substantially flexiblematerial; a flap integrally formed with the main body portion at theedge and comprising at least the second layer; and a hinge separatingthe flap from the main body portion, the hinge being defined by at leasta portion of the first layer having a reduced thickness, wherein theflap is folded back about the hinge towards the first surface of thefirst layer to substantially conceal the edge.
 2. The vehicle panel ofclaim 1 wherein the edge is at least one of a peripheral edge and aninternal edge.
 3. The vehicle panel of claim 1 wherein the vehicle panelis a headliner configured to be supported at a roof of a vehicle.
 4. Thevehicle panel of claim 3 wherein the edge defines an opening for asunroof in the main body portion.
 5. The vehicle panel of claim 1wherein the flap further comprises the first layer which provides areinforcement member at the edge when the flap is folded back towardsthe first surface of the first layer of the main body portion.
 6. Thevehicle panel of claim 1 wherein the portion of reduced thickness isformed by at least partially removing the first layer or by compressingthe first layer.
 7. The vehicle panel of claim 1 wherein the first layeris thinned from the second surface of the main body portion to providethe portion of the first layer having the reduced thickness and definingthe hinge.
 8. The vehicle panel of claim 1 wherein the first layer isthinned from the first surface of the main body portion to provide theportion of the first layer having the reduced thickness and defining thehinge.
 9. The vehicle panel of claim 1 wherein a portion of the firstlayer is substantially removed to provide the portion of the first layerhaving the reduced thickness and defining the hinge.
 10. The vehiclepanel of claim 1 wherein the hinge is further defined by a portion ofthe second layer having a reduced thickness.
 11. The vehicle panel ofclaim 10 wherein the second layer is thinned from a side opposite thefirst layer to provide the portion of the second layer having thereduced thickness and defining the hinge.
 12. A method of manufacturinga vehicle panel, the method comprising: forming a main body portionhaving a substantially rigid substrate and a substantially flexiblecover material coupled to the substrate, the substrate having an edge;providing an area of reduced thickness in the substrate, the area ofreduced thickness defining a living hinge; integrally forming a flapwith the main body portion, the flap being provided on a side of theliving hinge opposite the main body portion and comprising at a leastthe cover material; and folding the flap about the living hinge towardsthe substrate of the main body portion to substantially conceal theedge.
 13. The method of claim 12 further comprising forming an openingin the main body portion and wherein the edge defines the opening. 14.The method of claim 12 further comprising configuring the flap toinclude both the substrate and the cover material, the substrate on theflap providing a reinforcement member adjacent to the edge when the flapis folded about the living hinge.
 15. The method of claim 12 whereinproviding an area of reduced thickness in the substrate comprisesthinning the substrate from a surface opposite the cover material.